Blister packaging

ABSTRACT

Easy open blister packaging suitable for low density products, such as beverage tablets. In one embodiment, a blister package can have a forming layer with a flange and at least one blister cavity having a floor formed to slant at an angle of at least about 15 degrees relative to the forming layer flange, each blister cavity having a perimeter defining an open top and dimensioned to hold one product. The lidding layer can be a laminate sealed to at least the perimeter of the open top of each blister cavity, the lidding layer having a clear PET layer, an adhesive layer, a metal foil layer, a peripherally sealed desiccant layer and a pre-perforated sealant layer to seal to the forming layer, wherein the sealant layer perforations provide air communication between the blister cavity and the desiccant layer and the desiccant peripheral seal prevents air communication beyond the lidding layer periphery.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Patent Appl. No. 61/330,697, filed May 3, 2010, which is incorporated by reference in its entirety.

FIELD

The present products and methods relate to blister packaging, and more particularly to blister packaging suitable for beverage tablets.

BACKGROUND

Blister packages are known in the art to provide packaging for small consumer goods. In its basic form, a blister package can have a forming material layer with a preformed blister cavity (or cavities) and a lidding layer to seal a product (or products) within each cavity of the forming material layer. Typically, the forming layer can be made from a thermo-formable material such as polymer or other plastic or pressure-formable material such as aluminum. The lidding layer can be rupturable and made from sealing materials such as paper, polymers, aluminum foil or various combinations and laminates. Blister cavities can be arranged in many configurations, such as in a series to form a blister strip or in multiple rows and columns, to form, for example, a 2 by 3 blister pack. Often the blister cavity is formed to the general shape of the anticipated product to hold it in place so that movement and damage is minimized prior to product use. The forming layer is often transparent to allow product viewing.

Blister packages have many advantages. They can provide product visibility and are easy and relatively inexpensive to manufacture. Blister packs are suitable for several types of products such as hardware, electronics, chewing gum, pharmaceuticals, food, and the like.

One type of edible product suitable for containment in a blister package is a single serving water-soluble beverage composition in powdered or tablet form. Compositions in powdered form tend to be difficult to control. The alternative is to prepare a dry beverage composition in the form of a tablet. A challenge for beverage tablets can be that such tablets may not dissolve quickly in cold water or lack the proper structural strength to maintain its integrity during normal conditions of production, packaging, shipping and handling. This would be especially true for beverage tablet compositions that would need to be structurally strong enough to be pushed through a lidding layer of a blister pack, yet have a density low enough to allow them to dissolve quickly.

Attempts are known in the art to address product shape for beverage tablets contained in a blister pack. For example, U.S. Pub. No. 2007/0141204 to Xiong et al. describes various beverage tablet shapes to aid in rupturing a lidding layer when force is applied to the forming layer. Exemplary shapes include square edges facing the lidding layer and rounded surfaces facing the forming layer.

SUMMARY

Accordingly, provided herein are embodiments for blister packages that can have a forming layer and a lidding layer suitable for easy removal of low density tablets, such as beverage tablets, while maintaining a hermetic seal prior to use. In some embodiments, humidity level within the sealed cavity of the blister package can be maintained through the use of a hygroscopic layer (such as a desiccant layer) within the lidding layer exposed to the cavity of the forming layer.

Embodiments can include a blister package for storing and dispensing individual products that can have a forming layer having a flange in the range of about 50 to 500 microns and at least one blister cavity, the at least one blister cavity having a perimeter defining an open top and dimensioned to hold a product; and a lidding layer in the range of about 25 to 140 microns thick sealed to at least a portion of the perimeter of the open top of the at least one blister cavity, the lidding layer configured to be rupturable by applying a force of at most 15 lbs of force to the forming layer against a product having a hardness in the range of between about 3.5 to 4.5 kp (kilopond).

In one embodiment, the blister package forming layer can be PCTFE in the range about 75 microns thick and a lidding layer of about 75 microns thick.

In another embodiment, the blister package can have a forming layer that is a laminate comprising a PCTFE layer in the range of about 50 to about 120 microns thick bound to a PE EVOH PE layer in the range of about 35 to 55 microns thick, and a PVC layer in the range of about 200 to about 350 microns thick bonded to the PE EVOH PE layer.

In another embodiment, the lidding layer can be a laminate having a clear PET layer in the range of about 7.5 to 40 microns thick bonded to a metal foil layer in the range of about 6 to 30 microns thick, bonded to a sealant layer in the range of about 7 to 55 microns thick. Here, the sealant layer can provide a seal to at least the perimeter defining the open top of the blister cavity.

Optionally, embodiments can have scored lines of weakness to the PET layer of the lidding layer, where the lidding layer can be rupturable by an internally applied force of at most 13 pounds. PET scored lines of weakness can be laser cuts. Optionally, embodiments can include a hygroscopic layer disposed between the foil layer and sealant layer, the sealant layer further comprising pre-perforated openings to expose the hygroscopic layer to the blister cavity. The sealant layer can be a laminate of an adhesive layer bonded to sealant film. Optionally, where the sealant layer is a laminate of an adhesive film layer bonded to a heat sealant film, the package hygroscopic layer can be disposed between the foil layer and sealant layer, and the heat sealant film further having pre-perforated openings to expose the hygroscopic layer to the blister cavity.

In alternate embodiments, a blister cavity floor can be formed to slant at an angle of at least about 15 degrees relative to the forming layer flange.

The embodiments can be used to package products having hardness and integrity to allow an in-tact rupture through the lidding layer, an ability overcome surface tension when placed in water, and dissolve in less than 4 minutes. Optionally, the product can have a square edge positioned to be adjacent to the lines of weakness in the PET layer.

One embodiment can be a blister package for storing and dispensing individual products, having a forming layer having a flange and at least one blister cavity having a floor formed to slant at an angle of at least about 15 degrees relative to the forming layer flange, each blister cavity having a perimeter defining an open top and dimensioned to hold a product; and a lidding layer laminate sealed to at least the perimeter of the open top of each blister cavity, the lidding layer having a clear PET layer, an adhesive layer, a metal foil layer, a peripherally sealed desiccant layer and a pre-perforated sealant layer to seal to the forming layer, wherein the sealant layer perforations provide air communication between the blister cavity and the desiccant layer and the desiccant peripheral seal prevents air communication beyond a lidding layer periphery.

In a preferred embodiment, the blister package forming layer can be a laminate comprising a PCTFE layer of about 75 microns bound to a PE EVOH PE layer of about pref about 44 microns, and a PVC layer of about 254 microns bonded to the PE EVOH PE layer.

In an alternate preferred embodiment, the blister package lidding layer can be a laminate having a clear PET layer of about 18 microns bonded to a metal foil layer of about 10 microns, bonded to a sealant layer of about 25 microns, wherein the sealant layer provides a seal to at least the perimeter defining the open top of the blister cavity.

Other features of the present embodiments can include an outer package sleeve dimensioned for receiving the blister pack, the outer package having an open end and an opposed sealed end. Optionally, blister cavities can be provided in a two by three configuration.

Other features will become more apparent to persons having ordinary skill in the art to which the package pertains and from the following description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing features, as well as other features, will become apparent with reference to the description and Figures below, in which like numerals represent like elements, and in which:

FIG. 1 is a perspective view of an exemplary blister package of the present embodiments;

FIG. 2 is a top view of one blister cavity of an exemplary blister package;

FIG. 3 is a cross-sectional view of the blister cavity taken along section line A-A in FIG. 2;

FIG. 4 is bottom view of a portion of an exemplary desiccant layer taken along section line B-B in FIG. 3;

FIG. 5 is an alternate embodiment of an exposed desiccant layer;

FIG. 6 is a cross-sectional view of one blister cavity of an alternate embodiment of an exemplary blister package taken along section line A-A in FIG. 2;

FIG. 7 is a top view of an exemplary sleeve and blister pack;

FIG. 8 is a top view of an exemplary sleeve and partially removed blister pack;

FIG. 9 is a bottom view of an exemplary sleeve and partially removed blister pack;

FIG. 10 is a top view of an exemplary blister pack; and

FIG. 11 is a cross-sectional view of an alternate embodiment the blister cavity taken along section line A-A in FIG. 2.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Provided herein are embodiments for blister packages that can have a rigid forming layer and rupturable lidding layer suitable for easy removal of low density products while maintaining a hermetic seal prior to use. Exemplary products can include any number of food products, including, but not limited to, fast dissolving flavored beverage tablets. In some embodiments, humidity level within the sealed cavity of the blister package can be maintained or controlled through the use of a hygroscopic layer (such as a desiccant) within the lidding layer exposed to varying degree to the blister cavity of the forming layer. In other embodiments, the product shape can further aid in the ability to rupture the lidding layer for product removal. The embodiments can also feature a score (e.g., using a laser) to increase rupturability. The embodiments described herein generally illustrate a blister package suitable for containing multiple products, though any number of blister cavities can be considered within these embodiments. For example, in one embodiment 6 tablets per blister package are provided (e.g., a 2 by 3 configuration shown in FIGS. 1 and 7 through 10).

As described below, a single serving of product can be placed within each blister cavity, though other embodiments could provide multiple products within each cavity. The present embodiments can promote contamination free sharing and product portability. Exposure of one tablet or set of tablets to the atmosphere does not result in exposure of other tablets to the atmosphere since each blister cavity is hermetically sealed. This can allow for extended shelf life for the remaining sealed products (such as for at least 2 months). In the embodiments described below having an added sealed hygroscopic layer exposed to the blister cavity, shelf life can be extended even further to about 12 to 24 months.

The blister pack can optionally have lines of weakness in the forming layer between each of the blister cavities (not shown) so that individual blister cavities can be removed from the blister pack. The lines of weakness can be formed by perforation. In use, a consumer can still choose to retain the blister container in one piece until tablets are fully consumed to reduce litter.

Turning now to the Figures, there is illustrated in FIG. 1 a preferred embodiment of the present blister package 10 for a product 12 having a forming layer 24 with a flange area 36 and a plurality of blister cavities 32 sealed by a lidding layer 38. The embodiment of FIG. 1 shows an optional paperboard sleeve 34. It is noted that any number of blister cavities 32 are possible. For ease of understanding, FIG. 2 shows a top view of an embodiment with a single blister cavity 32. Forming layer 24 can be hermetically sealed to a lidding layer 38 as shown in cross section in FIG. 3.

The exemplary lidding layer 38 illustrated in FIG. 3 can be flexible, rupturable and/or peelable and many types of variations are possible. Lidding layer 38 can have an overall thickness in a range of about 25 to 140 microns and preferably about 75 microns. In one form, lidding material can have a total basis weight of about 38.9 lbs/ream. In a preferred embodiment, as illustrated in FIG. 3, lidding layer 38 can be rupturable and have a first layer 14, which can be a clear polyethylene terephalate (PET) layer having a thickness of about 7.5 to 40 microns and preferably of about 18 microns, and an adhesive layer 16 in a range of about 1.5 to 5 grams per meter squared and preferably about 3 grams per meter squared, to bond layer 14 to a metal foil layer 40. Metal foil layer 40 can be bonded to an optional hygroscopic layer, such as a desiccant layer 18 (described below), followed by a sealant layer 29, which can be bonded to flange 36 of forming layer 24.

The foil layer 40 component of lidding layer 38 is preferably aluminum based and can have about 1.50 grams per meter squared primer. The primer can be shellac, ethylene acrylic acid, methyl acrylic acid, and the like. The foil can be in the range of about 6 to 30 microns, though preferably about 10 microns. Sealant layer 29 can be an adhesive film layer 20 that can bond a heat sealant film 22 onto desiccant layer 18. Sealant layer 29 can be in a range of about 7 to 55 microns and preferably about 25 microns heat seal. Adhesive 20 could be a laminating adhesive (0.5-4 microns). The heat sealant could be an ethylene polymer blown film sealant or a cased polypropylene sealant in the range of 15-50 microns (preferably 35 microns).

Lidding layer 38 can be either easily ruptured or optionally peeled back by a user to provide product access. In embodiments where lidding layer 38 is peeled back (i.e., with no rupturing), sealant layer 29 can be a pressure sensitive adhesive (PSA) applied between lidding layer 38 and flange 36 of forming layer 24.

Lidding layer 38 is preferably ruptured by applying a force to blister cavity 32 of forming layer 24, especially for embodiments greater than 25 microns in overall thickness. The force to forming layer 24 is transferred to product 12, then to lidding layer 38. The product configuration and lidding rupturability should maintain product integrity during rupturing and removal. In embodiments above 25 microns, the lidding layer 38 can preferably be weakened by adding scoring lines 26, to aid in pushing the product/tablet through. Line (or lines) of weakness 26 (See FIGS. 2 and 3) can be placed across where lidding layer 38 spans blister cavity 32 to facilitate rupturing of the lidding 38, such as through a laser score. The lidding layer 38 line of weakness 26 can optionally be placed adjacent to a product's squared or other sharp edge 44, if present. It is also noted that where score lines 26 are added to the outside of lidding layer 38, they are offset from the sealant cuts 28, which expose the desiccant to the interior of the blister cavity.

Air/gas in blister cavity 32 can communicate with the optional hygroscopic layer (desiccant layer 18) of the lidding layer 38, such as shown at arrow 30 via sealant openings 28 in FIGS. 3 and 11. In FIG. 3, sealant layer 29 can have pre-perforated sealant openings 28 prior to adhesive lamination to the desiccant layer. In FIG. 11, opening 28 is only formed through the heat sealant film 22. It is noted that in this embodiment, adhesive film layer 20 does not block the moisture from the cavity headspace to reach the hygroscopic layer (scavenger) behind such adhesive. Several types of sealant layer 29 openings 28 and configurations are possible. FIGS. 4 and 5 show two such embodiments of sealant openings 28 to expose the desiccant layer 18 to the interior air cavity of a blister. Desiccant layer 18 in un-ruptured blisters can be sealed from ambient air migrating into the desiccant layer from the edges of the package or from ruptured blister cavities by a desiccant seal 42. As described in more detail below, desiccant seal 42 can be formed by hot edge scoring or a partial cut hot knife tool. In short, in embodiments having multiple blister cavities, desiccant seal 42 can protect the desiccant layer of unruptured blisters from exposure to ambient air.

In some embodiments, desiccant layer 18 can be a substantially continuous or discontinuous layer of desiccant granules. Preferably, the desiccant layer 18 is substantially continuous, containing granules that touch one another and allowing moisture migration throughout the layer 18. Thus, rupture of lidding layer 38 can potentially expose the entire desiccant layer 18 to ambient conditions and the subsequent loss of hygroscopy. This loss can be remedied by applying lidding layer 38 as a discreet (individual) label with its periphery sealed to ambient air than extends beyond the opening of each blister cavity to its surrounding flange and applied by, for example, a pressure sensitive adhesive.

Alternatively, lidding layer 38 can be adhesively laminated to forming layer 24 followed by sealing desiccant layer along each blister cavity 32, such as through the desiccant seal 42. Desiccant seal 42 could be formed through a melt perforation to facilitate the complete separation of each blister and preserve the moisture scavenger within the lamination. Alternate means to separate desiccant among the blister cavities 32 can be a mechanical cut with a hot knife or other mechanical score to cut through all but the sealant layer.

Forming layer 24 can be preferably at least translucent, and most preferably transparent, and/or colored. Forming layer 24 preferably provides a moisture and gas barrier. In one embodiment, forming layer 24 can be a poly-chlorotrifluoro-ethylene (PCTFE) material such as one sold under the trade name ACLAR by Honeywell. PCTFE is used extensively in pharmaceutical packaging and many other applications for its moisture barrier and chemical stability. The PCTFE layer can be in the range of about 50 to 500 microns and preferably about 75 microns. In another specific embodiment, forming layer 24 material can be a laminate of the following: a range of about 50 to 120 microns PCTFE and preferably about 75 microns; a range of about 2 to 4 grams per meter squared adhesive and preferable about 3.0 grams per meter squared; a range of about 35 to 55 microns PE EVOH PE and preferably about 44 microns; about 2 to 4 grams per meter squared adhesive and preferably about 3.0 grams per meter squared; and a range of about 200 to 350 microns PVC and preferably about 254 microns. EVOH can be regarded as an EVA (ethylene-acetic acid ethylene ester copolymer) modified material. In one form, the forming layer 24 can have a total basis weight of about 336.4 lbs/ream.

Exemplary products 12 to be contained within blister cavity 32 can have various shapes and be food products. For beverage tablet embodiments, product 12 is preferably: less than about 23 mm (and most preferably about 19 mm) in greatest outer diameter; has the hardness and integrity to allow an in-tact rupture through lidding layer 38 (e.g., ability to withstand about 15 lbs of force without significant disintegration, and preferably about 13 lbs of force); can overcome water surface tension; and can dissolve in less than about 2 to 4 minutes. The outer diameter measurement accounts for a typical 23 mm bottle neck. In preferred embodiments, the blister package 10 would allow a product 12 with a hardness factor of between about 3.5 to 4.5 kp (Kilopond) to remain in-tact during lidding layer 38 rupture. In this instance, a user can apply a force to the blister of the forming layer, which is transfer to the product to urge the product against and through lidding layer 38.

Preferably, where product 12 is a beverage tablet, it is premeasured for final desired beverage concentration in 8 ounces of water. Optionally, the product can effervesce when placed in water or water containing liquid, such as by emission of carbon dioxide gas. Product tablet 12 can be in the range of about 2.4 to 2.6 grams in weight and preferably in the range of about 2.42 and 2.56 grams. In some embodiments, product 12 can be shaped to facilitate rupture of the lidding layer 38, such as by having a squared (sharp) edge 144 adjacent the lidding layer as shown in FIG. 6. Optionally, product 12 beverage tablets can be have a premeasured amount of flavor and other ingredients, such as sweetener, vitamins, minerals and/or antioxidants. Indicia may be printed on product 12.

Optionally, as shown in FIG. 6 (where elements are comparable to FIG. 3, but with a 1 added before the element number), a floor 146 of the forming layer 124 blister cavity 132 can be angled/slanted to focus extraction forces to specific areas of the tablet 112 to enable more effective lid rupture and maintain tablet 112 integrity. In preferred embodiments the slant, shown by the arrows at an angle 148 can be about 15 degrees relative to the flange surface of forming layer.

Secondary and tertiary packagings are also possible to contain the blister package embodiments. For example, each blister pack 10 can be contained within a sleeve 34. In one form, sleeve 34 can be formed from preferably about 16 point (i.e., 16/1,000ths of an inch—range of about 10 to 40 point) SBS (solid bleached sulphite) paperboard or other paperboard with excellent stiffness and rigidity characteristics, and a very clean, glossy surface. Preferably, sleeve 34 is dimensioned for receiving blister pack 10 and has an open (or openable) end and an opposed sealed end. An openable end can have a closable flap (not shown) to prevent a blister pack from falling out. Also, FIG. 9 shows an optional hang tab 50 for added flexibility in product display.

A plurality of sleeved blister packs can be placed in a tray (not shown) for shelf display. Again, the tray can be a 16 pt. SBS paperboard. Each tray can also be placed in a corrugated shipping container. Thus, by way of example, a quantity scheme can be as follows: 6 product tablets per blister in a 2 by 3 configuration; 1 blister per paperboard sleeve; 12 blisters per tray; and 4 trays per corrugate shipper.

While preferred embodiments have been described in detail, variations and modifications can be effected within the scope of the presented embodiments. 

1. A blister package for storing and dispensing individual products, comprising: a forming layer having a flange in the range of about 50 to 500 microns and at least one blister cavity, the at least one blister cavity having a perimeter defining an open top and dimensioned to hold a product; and a lidding layer in the range of about 25 to 140 microns thick sealed to at least a portion of the perimeter of the open top of the at least one blister cavity, the lidding layer configured to be rupturable by applying a force of at most 15 lbs of force to the forming layer against a product having a hardness in the range of between about 3.5 to 4.5 kp (kilopond).
 2. The blister package of claim 1, wherein the forming layer is PCTFE in the range about 75 microns thick and the lidding layer is about 75 microns thick.
 3. The blister package of claim 1, wherein the forming layer is a laminate comprising a PCTFE layer in the range of about 50 to about 120 microns thick bound to a PE EVOH PE layer in the range of about 35 to 55 microns thick, and a PVC layer in the range of about 200 to about 350 microns thick bonded to the PE EVOH PE layer.
 4. The blister package of claim 1, wherein the lidding layer is a laminate having a clear PET layer in the range of about 7.5 to 40 microns thick bonded to a metal foil layer in the range of about 6 to 30 microns thick, bonded to a sealant layer in the range of about 7 to 55 microns thick, wherein the sealant layer provides a seal to at least the perimeter defining the open top of the blister cavity.
 5. The blister package of claim 4, further comprising scored lines of weakness to the PET layer of the lidding layer, wherein the lidding layer is rupturable by an internally applied force of at most 13 pounds.
 6. The blister package of claim 5, wherein the PET scored lines of weakness are laser cuts.
 7. The blister package of claim 4, further comprising a hygroscopic layer disposed between the foil layer and sealant layer, the sealant layer further comprising pre-perforated openings to expose the hygroscopic layer to the blister cavity.
 8. The blister package of claim 7, wherein the sealant layer is a laminate of an adhesive layer bonded to sealant film.
 9. The blister package of claim 1, wherein a blister cavity floor is formed to slant at an angle of at least about 15 degrees relative to the forming layer flange.
 10. A product for use in the blister package of claim 5, the product having hardness and integrity to allow an in-tact rupture through the lidding layer, an ability to overcome surface tension when placed in water, and dissolve in less than 4 minutes.
 11. The product of claim 10, further comprising a square edge positioned to be adjacent to the lines of weakness in the PET layer.
 12. A blister package for storing and dispensing individual products, comprising: a forming layer having a flange and at least one blister cavity having a floor formed to slant at an angle of at least about 15 degrees relative to the forming layer flange, each blister cavity having a perimeter defining an open top and dimensioned to hold a product; and a lidding layer laminate sealed to at least the perimeter of the open top of each blister cavity, the lidding layer having a clear PET layer, an adhesive layer, a metal foil layer, a peripherally sealed desiccant layer and a pre-perforated sealant layer to seal to the forming layer, wherein the sealant layer perforations provide air communication between the blister cavity and the desiccant layer and the desiccant peripheral seal prevents air communication beyond a lidding layer periphery.
 13. The blister package of claim 3, wherein the forming layer is a laminate comprising a PCTFE layer of about 75 microns bound to a PE EVOH PE layer of about pref about 44 microns, and a PVC layer of about 254 microns bonded to the PE EVOH PE layer.
 14. The blister package of claim 4, wherein the lidding layer is a laminate having a clear PET layer of about 18 microns bonded to a metal foil layer of about 10 microns, bonded to a sealant layer of about 25 microns, wherein the sealant layer provides a seal to at least the perimeter defining the open top of the blister cavity.
 15. The blister package of claim 4, wherein the sealant layer is a laminate of an adhesive film layer bonded to a heat sealant film, and the package further comprises a hygroscopic layer disposed between the foil layer and sealant layer, and wherein the heat sealant film further comprises pre-perforated openings to expose the hygroscopic layer to the blister cavity. 